Process of making artificial stone products



I UUI uul'll Uul l IUHO,

bj COATING 0R PLASTIC.

Examiner J. HAGGARD PROCESS 0F MAKING ARTIFICIAL STONE PRODUCTS originalFiled June 24. 1929 (ranalad yp5-ie- 1% @wuz-ed Lime Wzlerpr00z 9 i afll aegyrgyafe 0% aferra ggarai m%4/J/2m $5 rials that can be used, aswellas the vquality 140 used niust, furthermore, iiiix to 4a ratenteu nov.1l, 1vol.

o of economical manufacture.

Another object of the invention is te cembine lightness, strength Vandsuificietbardness in un-itsof thekind described. ,Another object istouse raw materials 15 vwhose physical and chemical properties render themsuitable to combine into a homoge- .neous mass under the process ltreatment explainedinthis specication. Another object is to obtainaconcrete ma- A" no terial which will mould, roll or press up into .cleansharply defined articles ofmanufacture or the uses indicated. 1 i IAnother object is to utlizea novel hardemngprocess for the manufactureof articles indicated from certain materials, as de- .scrbed'iw'iff:` u

i' Other objects and advantages will appear as the invention isdescribed in detaiL The single figure of the drawing s hovvs in soperspective one type of building unit, with a able aggregate combmationvt/1th the other 'elngrediets indicated, partieu-laily v table oingredients used in the iir'lvention,- In the manufacture of buildingunits of the kjnd described a number f considerations determine vtheavailability' of the raw mateof the product when `made u .Primarilyfevery ingredient used must e `c h eap' `1nd plentiful, also fairlyuniform 1n physical f and' chemical properties The ingredients vantagefwith the, aim of getting a nal produet superior in concrete propertiesto any one of the e ingredients alone, and for the purposes of f 'thlsinvention the mixed mass' must" mould,

articles f manufacture for the usefsffindii we L J el; f These severalconsiderations, with others,

suits being f obtained Wlth 'a class o seriai no. 370,886. -niviaea andune ppneauda mea marchi;

ms.- 432542. een e tion, abilityto hold nails, lightness', strength andtoughness, with freedom from inistir collection have resultedinfinnuinerable eii perimenfe efpaaiealer mixtures `and seai-ngprocesses for same, to cause them t y; tain any desired shapes underload.

Generaiyepeaking the bonding pfessee may be divided into those usingfiring perations, to brin about morer less 4fusin be# tween thedi erentIingredients of tlier Iiixf oo tureand those depending uponha clieniielreaction, as illustrated by the diierentkinds of cement and mortars...YFor some pur' o's manufacture of re fractories, ete., the rf processesare best,v or others` the cheiiiia 05 action gives as good and sometimesbetter fsults, lthis ,inventinfuses a precess f ffie latter classm., a

Ae iaieeted en the] drawing the ents used in the buildin unit materlal f70 this y i nventio n,-'and teir approximate amounts are: vesicularaggregate'of about 90% of theinal mixture. This aggregate Amay bederivedfrom a considerable range ofrocks, botlasto varietw and siie, even "I5downto spalls, and have du'nd sereeniigs large enough'to preserve avesielr 'strue- 1ture a sogive excellent results; Vgrades of worlrA aconsiderable variety of ein? ,Foreman ere; heveaep been feudto makensefnee- -ee goed fe- .C'lhfrs known commerclally as lire boxcliders.

IWith this aggregate, in substantially the .a5 aQlt stated of hard seek,geen as basalt,

er 'resistant eindef, are found Straelen, o l` A ranul'ated site, "Wl'ih106. COMPOSITIONS,

treatment, havin a sli ht degree of super-H.

heat. As the umts begm'to harden this degrec of superheat is increased,at the same time holding the pressure of the steam only a few, poundsabove the atmosphere. This degree of superheat, may be pushed to v:1-tinnperature up to' 150 degrees C. above which the gypsum content ofthe gypsite begins to ,4, change over to anhydride, in which form .it

2 does not react as favorably in the hardenin processasthe unalteredgypsum rock whic actsias a retarder during lthe moisture labstr ctionrecess. "fr e'rl of attempts have been' made to introduce gypsum as aningredient in artifi'v cial stone building units, using a firingprocess, but due to the molecular chan es brought about by the intenseheat of suc processes appliedto gypsum products, the final result inmany cases is loss of cohesion, brittleness and distortion. 'It has beenfound, on the contrary, that when psum is added as above. explained,comblned with hydrated g5. lime and cured kat suitable temperatures `un.

derv 'a lcontrollable steam 'application of the heat,' that a ve'rysuperior building unit ,of evenr complicated shapes can be produced.tArtificial stone l units, vfabricated Yas exfy plainedabove, havemoreover, been found to 40 fshow a very slight moisture absorption inuse, which is a highly desirable quality in such articles'.` It iswellknown that lime bonded bricks' have a much lower absorption ythan scement bonds, and becauselof the earthy nature 'of the gypsite fillermaterial used in the units lof this invention'prhardening stressesare'largely eliminated while the closure'of the aggregate vesicles isexceptionallyplose ,w and homogenous.' i. l, Effi watecroon com ound {Ihave ,oun a u e colloidal silicate of calcium and aluminunmmm e moresodium silicate can also be used. f. Any eslre co or 1n e units manu'-,',fyacture'd canbe had b suitable pigments added as anal step t emixing operation, .,hweventhe lime and gypsite ingredients acne giv lagood natural color with m'o'stagg1`gteS./ t l 'l M ""z ,ff'lfhis'application 'is a' divisionof applica- ,tion Seriana. 370,886 'filedJune 24, 1929, ,uae-.Artificial Seneffe t ne No. A1793 172. i@ Whatis.claimed as new 1s: u

' 1- The Proces-Of makin articls'tiie 51mm@ comme 0R PLASTIC. f mivesicular aggregate, lime and gypsite and subsequently applying heat bya steam controlled operation.

2. An apertured artificial stone unit in' which the area o the aperturesb'ears'a con- 76 siderable 'ratio to the area of the unit'walls, thematerial of the walls consisting of a mixture 0f Sitelm and veslllaraggrer'. gate, in urated by steam treatment at a temerature less than,or slightly above, 150 75 3. A formed concrete unit provided withapertures, surrounded 'by -wallsl relatively thi-n with respect to theaperture areas, said walls being made of a material composed of s0 lime,a'gypsite filler, anda vesicular aggre-c gate, hardeneda's alconcreteunder 'a temperature of approximately 150 degrees C; "f 4,` lheu process of hardening "a concrete material containing gypsum, lime and'a 735 vesicular aggregate, which consists in ,heats ing a mixedjmass ofthese materials bysteam treatment'pto a temperature low enough to ivoidchanging the gypsum content to'anhyr1 e.` "1 ""5. A process of'dryingand hardening arti-z ticial stone units made of a materialcontain'- 1ng gypsum, limela'nd a vesicularl aggregate which lconsistsin heating a mixedmass of .thesematerials,"' sh'aped asa `tinishe'dunit,i2* under low pressure steam of a" slight degree of 'superheat andgradually 'increasing 'the amount o f superheat to a temperature lessthan suiiicient to de composethe 'A concrete articial stoneunit of ama-1l-03 terial containing gypsum, lime and a'vesic'ular a gregate,hardened by steam treatment. y' e process of preparing' artificial stoneumts which consists in reducing a 'vesiculaigr aggregate to a' uniformsize, mlxing it with 105 ,gyps'lte and lime to a plastic consistency,shapmg the' unit',A and hardening it by exposureto steami 'j Q. `Theprocess of making an artificial stone vumtwhich consists grindingtogetheri .gyps1te,li'me and vesicular aggregate in the ldry and addin'vsuiiicient 'waterjto form a plast1c' m'as`s, al apted to shapingoperations such as moulding, pressing or rolling to defi- ,v

tilh

lai f ,f .i l 1- n ',Abuildin 'material formation process consisting inya ding substantia'll 81/2% hy- Ydrated,lixv'nepand'1% granulate 'gypsiteto vesicular aggregate iny a: dry grindingy operation and temperin withwatercontainme ,a small ammini 0j vater-.Proong C01- ,loldsg H ,10,.Tne'process I of. fabricating artificial 5stone products which'consists in grinding together clnders and gypsitewith the'addtionif" oflime and suiiicient water to form a coherent plastlc mass, moulding themass into any des1red shape, and ex o sing itl to steam' treatment untilhardened.i

u V5 units which consists in grinding together 11. The 4process offabricating'. artificialSim pressure to soldity.

JERRE HAGGARD.

